Highly recyclable beverage pods and method of manufacture

Abstract

A method of manufacture for highly recyclable beverage pods, wherein the method includes providing a beverage pod having a cavity and an interior surface within the cavity, placing a filter disc into the cavity of the beverage pod, adhering a formed filter material within the cavity of the beverage pod, filling the formed filter material adhered to the interior of the cavity with beverage material, having a headspace atmosphere, modifying the headspace atmosphere within the cavity, sealing the cavity with an airtight lid, and discharging the beverage pod into a secondary packaging operation, producing a highly recyclable beverage pod containing a cavity with a shell, a filter disc disposed within the cavity, a formed filter material adhered to an interior surface of the cavity, a beverage material within the formed filter material, and an airtight lid configured to seal the filter disc, the formed filter material, and the beverage material.

1 . A method of manufacture for beverage pods, wherein the method comprises:
 providing a beverage pod having a cavity and an interior surface within the cavity;   removing a filter disk from a bulk supply using vacuum picking:   placing filter disc into the cavity of the beverage pod;   adhering a formed filter material within the cavity of the beverage pod, wherein adhering the formed filter material within the cavity of the beverage pod comprises:
 receiving a pre-formed filter material; 
 placing the pre-formed filter material within the cavity of the beverage pod; and 
 sealing the pre-formed filter material to the interior surface; 
   filling the formed filter material adhered to the interior of the cavity with beverage material, having a headspace atmosphere;   modifying the headspace atmosphere within the cavity;   sealing the cavity with an airtight lid; and   discharging the beverage pod into a secondary package operation.   
     
     
         2 . The method of  claim 1 , wherein the beverage pod is a single-serving beverage pod. 
     
     
         3 . The method of  claim 1 , wherein the beverage pod is a multi-serving beverage pod. 
     
     
         4 . The method of  claim 1 , wherein a beverage pod shell is comprised of aluminum material. 
     
     
         5 . The method of  claim 1 , wherein the beverage pod shell is comprised of an aluminum alloy material. 
     
     
         6 . The method of  claim 1 , wherein the method further comprises de-nesting the beverage pod, wherein de-nesting a beverage pod comprises:
 receiving a plurality of aluminum beverage pods; and   de-nesting a beverage pod from the plurality of aluminum beverage pods;   
     
     
         7 . The method of  claim 1 , wherein the method further comprises filter material forming, wherein filter material forming comprises:
 forming filter material; and   press-forming the formed filter material.   
     
     
         8 . The method of  claim 1 , wherein the pre-formed filter is press-formed into a design comprising pleats and creases. 
     
     
         9 . The method of  claim 1 , wherein the cavity of the beverage pod is comprised of a polymeric coating. 
     
     
         10 . The method of  claim 1 , wherein filling the cavity of the beverage pod with beverage material is accomplished using an auger feeder. 
     
     
         11 . The method of  claim 1 , wherein filling the cavity of the beverage pod with beverage material is accomplished using a volumetric filler. 
     
     
         12 . The method of  claim 1 , wherein modifying the headspace atmosphere within the interior cavity comprises filling the cavity with an inert gas. 
     
     
         13 . The method of  claim 1 , wherein modifying the headspace atmosphere within the interior cavity comprises filling the cavity with nitrogen. 
     
     
         14 . The method of  claim 1 , wherein the airtight lid comprises a peelable lid. 
     
     
         15 . The method of  claim 1 , wherein the airtight lid is comprised of an aluminum foil material and polymeric coating. 
     
     
         16 . The method of  claim 1 , wherein sealing the cavity with an airtight lid comprises sealing the cavity using a heat sealer. 
     
     
         17 . The method of  claim 1 , wherein the method is performed by an automated fill and seal machine. 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . The method of  claim 1 , wherein discharging the beverage pod into a secondary package operation further comprises singulation of the beverage pod. 
     
     
         22 . The method of  claim 1 , wherein sealing the pre-formed filter material to the interior surface comprises convection heat sealing. 
     
     
         23 . The method of  claim 1 , wherein sealing the cavity with the airtight lid comprises convection heat sealing.